EXHAUST MANIFOLD FLIP MOD TO FIT THE G60 INTAKE MANIFOLD AND A K-14 TURBO

[AudiVWguy]

OK,
So I finally got around to taking off the Callayway system and installing the K-14. The main reason for me was I wanted to get more useable midrange torque.
After taking off the old system, I found this is much easier using a small mirror to get the socket on the bolt heads than the braille method..........

As you probably have seen, the shape of the G60 manifold doesn't leave any room for the turbo to sit. By flipping the exhaust manifold pointing down there is now room to add a turbo. Yes, you will have to fabricate oil in/out, air in/out, and exhaust out, but each part of the puzzle wasn't that bad. Your situation may be easier than mine was.
Having a spare engine or head sitting around will allow you to see where your clearance issues will be.
Some spots to look at will be where the two flanges touch, you will need to remove material, mostly on the exhaust side, to get the two manifolds to set correctly.

Another spot is where one of the turbo mounting bolts interferes with the intake mounting bolts.


You will need to grind the area around the bolt and some the bolt head for clearance.
Next, on the intake manifold, the bolt that fits above the turbo flange bolt has to be shortened to get past that area. The base that the bolt contacts has to be shortened about 1/2 in. and the bolt has to be shortened also. They must all go into the head the same length.

Once you get the turbo installed check the shift linkage, it will have to be "adjusted" down to clear the housing.



That was some of the more complex problems, the rest of the shots just give you an idea of the rest of the install. All the intercooler piping is mostly from the Saab turbo. I decided to go with a 3 inch down pipe for as little back pressure as  possible.









I also ported the exhaust side of the K-14 (which I will talk about in a different thread. So, I've got about 500 miles on this setup and I must say I'm a bit underwelmed. Everybody talks about how great the K-14 is but I'm not impressed. Sure, it'll give you 20 psi of boost instantly, but there's not that much torque increase. I do need to switch back to the Giles pump, but fueling isn't really an issue. Right now there is only a little smoke at full throttle.
On the plus side, EGT's are extremely good. Cruzing at 70 mph is 590 to 650 degrees F. Fourth gear pull till redline will give me about 975 F and instantly go away when I let off. The 3 in, down pipe with the ported exhaust has relieved the bottle-neck at the exhaust and dropped the EGT's a lot. I am also injecting straight water above 12 psi which helps .
Things to try next, put on the Giles pump. Although more fuel is more heat. I've also wondered what would be the next slightly larger compressor side for the turbo. It seems to me there is not that much air volume that comes with the boost pressure. A little bit larger shouldn't give up too much spool up.

Sorry this is so long, any suggestions on what to try next would be helpful.
Cheers,
-JB

[AudiVWguy]

I'm saying that 15 psi on the K-14 seems kinda lame, compared to 15 psi on the Callaway. I know that 15 psi should be 15 psi, no matter what size compressor is providing it. You would think that if the compressed air was really heating up, It would show up as higher numbers on the EGT? I agree that 15-18 psi is out of its maximum efficiency range, I'm not sure what its efficiency would be at 18 psi.
If I were to make a hybrid turbo, kept the hot side the same, what would be the next size up for the compressor side for the K-14?   

[AudiVWguy]

This is the AAZ one.